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  5. Installation & Operation Manual

Navien NHB-055 Installation & Operation Manual - Contents

Manual is about: NHB series Condensing Boilers

Summary of NHB-055

  • Page 1

    Warning if the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. What to do if you smell gas...

  • Page 2

    2 requirements for the state of massachusetts notice before installation this appliance must be installed by a licensed plumber or gas fitter in accordance with the massachusetts plumbing and fuel gas code 248 cmr sections 2.00 and 5.00. Important: in the state of massachusetts (248 cmr 4.00 & 5.00)...

  • Page 3: Contents

    Contents 3 contents 1. About the boiler 6 1.1 included items 6 1.2 accessories 6 1.3 specifications 7 1.4 components 9 1.5 dimensions 11 1.6 rating plate 12 2. Installing the boiler 13 2.1 choosing an installation location 13 2.2 mounting the boiler to the wall 15 3. Installing the system piping 16 ...

  • Page 4: Safety Information

    4 safety information the following safety symbols are used in this manual. Read and follow all safety instructions in this manual precisely to avoid unsafe operating conditions, fire, explosion, property damage, personal injury, or death. Danger indicates an imminently hazardous situation which, if ...

  • Page 5

    Safety information 5 caution ● do not turn on the boiler unless the water and gas supplies are fully opened. Doing so may damage the boiler. ● do not use this boiler for anything other than its intended purpose, as described in this manual. ● do not remove the front cover unless the power to the boi...

  • Page 6: 1.    About The Boiler

    6 about the boiler 1.1 included items when you open the box, you will find the following items with the boiler. Check the box for each of the following items before installing the boiler. Installation & operation manual, user’s information manual quick installation manual 2 in vent termination caps ...

  • Page 7

    About the boiler 7 1.3 specifications the following tables list the specifications for the boiler. Additional specifications for water, gas, electricity, and vent connections are provided in the installation section. Space heating specifications navien condensing boiler space heating ratings other s...

  • Page 8

    8 about the boiler general specifications item nhb-055 nhb-080 nhb-110 nhb-150 dimensions 17in (w) x 12in (d) x 24in (h) 17in (w) x 13in (d) x 24in (h) weight 73 lb (33 kg) 80 lb (36 kg) installation type indoor wall-hung venting type forced draft direct vent ignition electronic ignition natural gas...

  • Page 9

    About the boiler 9 1.4 components the following diagram shows the key components of the boiler. Component assembly diagrams and particular parts lists are included in the appendixes. Intake air air filter front panel exhaust flue duct space heating supply aps pcb power switch air vent connection lwc...

  • Page 10

    10 about the boiler dual venturi ignition transformer igniter & flame rod primary heat exchanger mixing gas guide secondary heat exchanger condensate trap gas connection space heating return gas valve fan & motor metal fiber premix burner.

  • Page 11

    About the boiler 11 1.5 dimensions the following diagrams show the dimensions of the boiler and the table lists the supply connections. 23.6" (600 m m ) supply connections description diameter a air intake 2 in b exhaust gas vent 2 in c air vent connection 3 / 4 in d rubber grommet 1 in e space heat...

  • Page 12

    12 about the boiler 1.6 rating plate the navien nhb boilers come from the factory configured for use with natural gas (ng). Before starting the installation, check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type, gas pressure, water pressure, and ele...

  • Page 13

    Installing the boiler 13 2.1 choosing an installation location when choosing an installation location, you must ensure that the location provides adequate clearance for the boiler, adequate venting and drainage options, and sufficient access to gas, water, and electrical supplies. Carefully consider...

  • Page 14

    14 installing the boiler clean, debris and chemical-free combustion air ● do not install the boiler in areas where dust and debris may accumulate or where hair sprays, spray detergents, chlorine, or similar chemicals are used. ● do not install the boiler in areas where gasoline or other flammables a...

  • Page 15

    Installing the boiler 15 2.2 mounting the boiler to the wall navien nhb boilers come with an upper mounting bracket that is pre-drilled at 16 in (400 mm) on center for easy installation on standard wall studs. If the strength of the wall is insufficient or if the framing is non-standard or uneven, r...

  • Page 16

    16 installing the system piping prior to connecting plumbing to the boiler, flush the entire system to ensure it is free of sediment, flux, solder, scale, debris or other impurities that may be harmful to the system and boiler. During the assembly of the heating system, it is important to keep the i...

  • Page 17

    Installing the system piping 17 oxygen elimination this boiler may only be installed in a pressurized closed-loop heating system, free of air (oxygen) and other impurities. To avoid the presence of oxygen, ensure all of the air is removed from the system during commissioning via strategically placed...

  • Page 18

    18 installing the system piping low water cut off (lwco) device internal lwco the navien nhb boiler is equipped with a factory-installed, pressure-sensing type low water cutoff (lwco) device. The minimum operation pressure for this device is 6 psi by default. Note when the built-in water pressure se...

  • Page 19

    Installing the system piping 19 pressure relief valve to complete the space heating system installation, you must install a 3 / 4 in, 30 psi (max.) pressure relief valve on the space heating hot water outlet. An asme approved hv pressure relief valve for space heating system is supplied with the boi...

  • Page 20

    20 installing the system piping 3.1.3 space heating system piping when connecting the space heating system, follow these guidelines: ● carefully tighten all connections to avoid damage to fittings. ● after installing the boiler, check the space heating system's operation and inspect for leaks. The o...

  • Page 21

    Installing the system piping 21 pq curves nhb-055/080 nhb-110 nhb-150 0 2 4 6 8 10 12 14 16 18 20 0 1 2 3 4 5 6 7 8 h [ft] 0 2 4 6 8 10 12 14 16 18 20 0 2 4 6 8 10 12 h [ft] 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 0 2 4 6 8 10 12 14 16 h [ft ] q[gpm] q[gpm] q[gpm].

  • Page 22

    22 installing the system piping 3.2 connecting the condensate drain the navien nhb boiler creates condensation when it operates. This condensation has an acidic ph of 3-5. Follow all local codes and regulations when disposing of condensate from the boiler. We recommend draining the condensate into a...

  • Page 23

    Installing the system piping 23 3.2.1 condensate neutralizer kit warning ● to avoid damaging the appliance, the neutralizer inlet and discharge must be lower than the condensate drain. ● do not allow exhaust flue gases to vent through the neutralizer. Leakage can cause injury or death from carbon mo...

  • Page 24

    24 installing the system piping maintenance periodically monitor the level of media in the neutralizer and test the ph level at the outlet. We recommend an annual ph test using recognized test strips or an electronic ph meter to obtain precise measurements. Replace the neutralizing media when the ph...

  • Page 25

    Installing the system piping 25 contaminant maximum allowable level total hardness 200 mg/l (12 grains/gallon) aluminum 0.05 to 0.2 mg/l chloride 250 mg/l copper 1.0 mg/l iron 0.3 mg/l manganese 0.05 mg/l ph 6.5-8.5 sulfate 205 mg/l 2. Close the manual and automatic air vents and the boiler drain va...

  • Page 26

    26 installing the system piping thermostat configuration for the air handler interface set the pcb dip sw2 #7 to down position (off) to use a thermostat with the air handler. 1 2 3 4 5 6 on 1 2 3 4 5 6 7 8 on refer to the "3.1.1 guidelines for a space heating installation" on page 34 for wiring conn...

  • Page 27

    Installing the system piping 27 3.5.2 system application - zone system with zone valves make-up water backflow preventer pressure reducing valve additional zone zone #2 zone #1 system pump air separator expansion tank not to exceed 4 pipe dia or max. 12" zone valve (typical) boiler pump note ● syste...

  • Page 28

    28 installing the system piping 3.5.3 system application - zone system with pumps make-up water backflow preventer pressure reducing valve additional zone zone #2 zone #1 air separator not to exceed 4 pipe dia or max. 12" boiler pump expansion tank note ● system application drawings are intended to ...

  • Page 29

    Installing the system piping 29 3.5.4 system application - air handler system air flow air handler system pump (boiler pump) make-up water air separator expansion tank backflow preventer pressure reducing valve note ● system application drawings are intended to explain the system piping concept only...

  • Page 30

    30 installing the system piping 3.5.5 system application - dhw system with indirect tank make-up water backflow preventer pressure reducing valve dhw outlet dhw inlet indirect tank anti-scald mixing valve system pump boiler pump dhw pump air separator expansion tank note ● system application drawing...

  • Page 31

    Installing the system piping 31 3.6 examples of electrical connections warning improperly connecting the electrical supplies can result in electrical shock and electrocution. Follow all applicable electrical codes of the local authority having jurisdiction. Connecting the electrical components shoul...

  • Page 32

    32 installing the system piping 3.6.3 wiring diagram - the navien smartzone + when navien boilers are used with a navien smartzone+ zone pump controller, an rs-485 data communication link is established through the ready-link connection. This allows the controller and the boiler to share operational...

  • Page 33

    Installing the system piping 33 3.6.4 wiring diagram - generic zone system with zone valves cn12 cn10 cn27 cn23 cn24 cn29 cn30 cn25 zone1 t/s zone2 t/s zone3 t/s zone4 t/s zone5 t/s zone6 t/s zone1 valve zone2 valve zone3 valve zone4 valve zone5 valve zone6 valve t/t lwco ac24v output t/t ch t/t dhw...

  • Page 34

    34 installing the system piping 3.6.6 wiring diagram - air handler cn12 cn10 cn27 cn23 cn24 cn29 cn30 cn25 thermostat lwco ac24v output t/t ch t/t dhw temp. System return (optional) temp. System supply (optional) if you are using the navien manifold system, connect the pump wires to the system pump....

  • Page 35

    Installing the system piping 35 3.6.8 wiring diagram - optional supply/return temperature sensors cn12 cn10 cn27 cn23 cn24 cn29 cn30 cn25 lwco ac24v output t/t ch t/t dhw temp. System return (optional) temp. System supply (optional) temperature sensor thermal insulation cable tie note refer to "6.1 ...

  • Page 36

    36 connecting the gas supply warning ● before connecting the gas supply, determine the gas type and pressure for the boiler by referring to the rating plate. Use only the same gas type indicated on the rating plate. Using a different gas type will result in abnormal combustion and malfunction of the...

  • Page 37

    Connecting the gas supply 37 note ● tighten the boiler connection valves with care to avoid damage. ● the gas connection fitting on all boilers is 3 / 4 in. ● 1 / 2 in rigid pipe can be used; refer to the sizing tables on the proceeding pages for limitations. Avoid using 1 / 2 in corrugated connecto...

  • Page 38

    38 connecting the gas supply 4.1 gas pipe sizing tables the following tables are referenced from 2012 national fuel gas code for reference only. Please consult the gas pipe manufacturer for actual pipe capacities. Maximum natural gas delivery capacity in cubic feet (ft 3 ) per hour (0.60 specific gr...

  • Page 39

    Connecting the gas supply 39 maximum liquefied propane delivery capacity in thousands of btu/h (0.5 in wc pressure drop) pipe size length (including fittings) 10 ft (3 m) 20 ft (6 m) 30 ft (9 m) 40 ft (12 m) 50 ft (15 m) 60 ft (18 m) 80 ft (24 m) 100 ft (30 m) 125 ft (38 m) 150 ft (45 m) 175 ft (53 ...

  • Page 40

    40 connecting the gas supply 9. Remove the front cover by loosening the 4 phillips head screws securing it to the case. 10. Loosen the screws indicated in the figure below and connect a manometer to the pressure port. Reset the manometer to zero before use. Digital pressure manometer 11. Re-open the...

  • Page 41: 5.    Venting The Boiler

    Venting the boiler 41 warning improper venting of the boiler can result in excessive levels of carbon monoxide, which can lead to severe personal injury or death. This boiler must be vented in accordance with the “venting of equipment” section of the latest edition of the ansi z223.1/nfpa 54 natural...

  • Page 42

    42 venting the boiler ref description canadian direct vent installations 1 us direct vent installations 2 a clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) b clearance to window or door that may be opened 36 in (91 cm) 12 in (30 cm) c clearance to permanently clos...

  • Page 43

    Venting the boiler 43 to use non-direct venting for the boiler: 1. Insert the termination end cap into the intake air duct. Do not glue the end cap, to allow for easy removal and cleaning of the cap. Vent termination cap 2" coupling 2" vent pipe 2" 2. Provide two openings to allow for circulation of...

  • Page 44

    44 venting the boiler ref description canadian non-direct vent installations 1 us non-direct vent installations 2 a clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) b clearance to window or door that may be opened 36 in (91 cm) 48 in (120 cm) below or to side of op...

  • Page 45

    Venting the boiler 45 5.2 selecting vent pipe materials venting requirements differ in the us and canada. Consult the following chart or the most recent edition of ansi z223.1/nfpa 54 or can/cga b149.1, as well as all applicable local codes and regulations when selecting vent pipe materials. Do not ...

  • Page 46

    46 venting the boiler indoor boiler installation venting examples the following are some possible indoor venting options: ● 2 in or 3 in two-pipe sidewall venting 12" (300 mm) min. 12" (3 00 mm ) min. Exhaust gas exhaust gas interior view exterior view intake air intake air 5.4 terminating the vent ...

  • Page 47

    Venting the boiler 47 ● 2 in or 3 in two-pipe vertical venting – intake and exhaust pipes do not have to terminate in the same area. 12" (300 mm) min. 12" (300 mm) min. 36" (900 mm) min. 12" (300 mm) min from any obstruction (above, below, left, or right) exhaust gas intake air ● concentric roof ven...

  • Page 48

    48 setting the dip switches caution do not remove the front cover unless the power to the boiler is turned off or disconnected. Failure to do so may result in electric shock. The boiler has 2 sets of dip switches on the main circuit board (pcb) and 2 sets of dip switches on the front panel. Dip swit...

  • Page 49

    Setting the dip switches 49 dip switch 2 (2 switch unit) the dip sw 2 on the front panel configures settings for the type of gas. Before changing the settings, lift the rubber cover to access the front panel dip switches. 2 on ng lp 2 on 1 2 3 4 5 6 7 8 9 10 1 2 on on switch function setting 2 gas t...

  • Page 50

    50 connecting the power supply warning improperly connecting the power supply can result in electrical shock and electrocution. Follow all applicable electrical codes of the local authority having jurisdiction. In the absence of such requirements, follow the latest edition of the national electrical...

  • Page 51

    Installation checklist 51 after installing the boiler, review the following checklist. You should be able to answer “yes” to all of the items in the checklist. If not, review the appropriate sections to complete the installation. To troubleshoot any operational problems refer to “troubleshooting” in...

  • Page 52

    52 installation checklist connecting a pressure relief valve yes no have you installed an approved pressure relief valve on the boiler? Does the rating of the pressure relief valve match or exceed the maximum btu rating of the boiler? Is the pressure relief valve 3 / 4 in on the space heating outlet...

  • Page 53

    Installation checklist 53 pcb dip switch setting (dip sw 2, set of 8) yes no is switch #1 set correctly for return water control (on) or supply water control (off)? If continuous boiler operation is required, is switch #7 in the up (on) position? If high temperature venting has been installed (cpvc ...

  • Page 54: 9.    Operating The Boiler

    54 operating the boiler 2. Press the + (up) or – (down) buttons until the desired temperature appears on the display. Mode you can adjust the temperature while the display is flashing. Once the display stops flashing, the temperature setting is stored. Note ● the outdoor reset control will take prec...

  • Page 55

    Operating the boiler 55 9.3 viewing basic information to view information about the boiler, press the mode button three times. “info” will appear on the display. Mode press the + (up) or – (down) buttons to switch between the information types. Display description psi o/r s r pri space heating suppl...

  • Page 56

    56 operating the boiler display description psi o/r s r pri space heating return water temperature (°f) psi o/r s r pri not available psi o/r s r pri not available psi o/r s r pri not available psi o/r s r pri outdoor air temperature (°f) (from outdoor temperature sensor) psi o/r s r pri outdoor res...

  • Page 57

    Operating the boiler 57 display description psi o/r s r pri blower fan motor target rpm (x 10) psi o/r s r pri blower fan motor current rpm (x 10) psi pri o/r s r aps target voltage psi o/r s r pri aps current voltage psi o/r s r pri exhaust gas temperature (°f) psi o/r s r pri model type (55, 80, 1...

  • Page 58

    58 operating the boiler display description psi o/r s r pri dhw pump status psi o/r s r pri overheating sensing (htl) status psi o/r s r pri dual venturi status psi o/r s r pri low water cut-off (lwco) status psi o/r s r pri air handler interface output psi o/r s r pri dhw priority status to exit se...

  • Page 59

    Operating the boiler 59 note ● if you enter an incorrect password 10 times or make no inputs 5 minutes, the boiler will return to normal mode. ● to return to the previous mode, press the reset button. ● the factory default password is “1234”. ● if you make no inputs for 10 seconds in the parameter e...

  • Page 60

    60 operating the boiler setting the lowest outdoor temperature display description psi o/r s r pri lowest outdoor temperature (°f) psi o/r s r pri lowest outdoor temperature not in use this mode is used to configure the lowest outdoor temperature. The boiler will operate at the high end of the suppl...

  • Page 61

    Operating the boiler 61 setting the pump freeze protection temperature display description psi o/r s r pri pump freeze protection temperature (°f) this menu is used to configure the circulation pump freeze protection temperature. When the space heating supply temperature stays below the set value fo...

  • Page 62

    62 operating the boiler setting the burner-on temperature differential display description psi o/r s r pri burner-on temperature (°f) during space heating, the boiler turns on the burner when the space heating supply temperature is below the burner-on temperature. Burner-on temperature range range r...

  • Page 63

    Operating the boiler 63 setting the return absolute min temperature display description psi o/r s r pri return absolute min set point (°f) this menu can be used to change the minimum return temperature range in return control mode. When custom mode is configured in outdoor reset control mode, change...

  • Page 64

    64 operating the boiler setting the dhw mode-system pump display description psi o/r s r do not use system pump (no) psi o/r s r use system pump (yes) use this menu to set system pump operation for dhw mode. ● default: off setting the ch mode-dhw pump display description psi o/r s r do not use dhw p...

  • Page 65

    Operating the boiler 65 setting the space heating min heat capacity display description psi o/r s r pri dhw min heat capacity (%) this menu is used to configure the desired dhw minimum capacity. When the boiler operates in normal mode, the minimum dhw capacity is limited to the set value (%). ● defa...

  • Page 66

    66 operating the boiler setting a new password display description psi o/r s r change password this menu may be used to set a new password to access the parameter setting menu. To set a new password: 1. Move to “*.Psc” and press the mode button. The current password is displayed, with the first digi...

  • Page 67: 10.    Appendixes

    Appendixes 67 10.1 gas conversion this boiler is configured for natural gas at the factory. If conversion to propane gas is required, use the conversion kit supplied with the boiler. Warning this conversion kit must be installed by a qualified service agency* in accordance with navien’s instructions...

  • Page 68

    68 appendixes 7. Remove the pcb assembly. 8. With the internal components exposed, locate the gas inlet pipe and the gas valve in the middle of the unit, as shown in figure 2. Gas valve gas inlet pipe figure 2. Nhb series internal components 9. Use a phillips screwdriver to remove the two screws at ...

  • Page 69

    Appendixes 69 warning ● do not adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. ● attempting to alter or measure the gas valve outlet pressure cou...

  • Page 70

    70 appendixes 17. Turn on the gas and water supply to the boiler. 18. Measure and adjust the gas/air ratio. Option 1. Using combustion analyzer (recommended) a. Loosen the screw, rotate the plate and remove the gasket to access the emissions monitoring port as shown in figure 7. B. Insert the analyz...

  • Page 71

    Appendixes 71 option 2. Using digital manometer a. Open the offset pressure port by loosening the screw two turns as shown in figure 9. Digital pressure manometer figure 9. Connect digital pressure monometer b. Connect a manometer to the offset pressure port. For dual port manometers, use the positi...

  • Page 72

    72 appendixes 10.2 wiring diagram color c ode b o r w y bk br gy : blue : or ange : r ed : w hit e : y ello w : black : br own : gr een/y ello w if an y of the or ig inal wir es as supplied the boiler must be replac ed , they must be r eplac ed their equiv alen t. Fm fan m ot or y bk r o w cn8 cn17 ...

  • Page 73

    Appendixes 73 10.3 ladder diagram.

  • Page 74

    74 appendixes 10.4 component assembly diagrams and parts lists 10.4.1 case assembly 10 1 3 4 2 8 7 9 9 5 6 9 10 1 3 4 2 8 7 9 9 5 6 9.

  • Page 75

    Appendixes 75 # description part # remark 1 case 20030085a nhb-110/150 20030088a nhb-055/080 2 cover 30013463a 3 pcb 30013044a 4 front panel 30013041a 5 exhaust pipe assembly 30008673a 6 intake air duct assembly 30008662b 7 intake air fillter 20007667a 8 air pressure sensor 30010238a 9 rubber ring 2...

  • Page 76

    76 appendixes 10.4.2 heat exchanger and waterway assembly 13 12 11 7 7 2 5 4 14 16 6 19 7 3 3 18 3 21 6 2 22 1 9 14 15 12 10 12 12 12 7 7 20 12 7 12 2 19 17 12 12 8 7.

  • Page 77

    Appendixes 77 # description part # remark 1 heat exchanger assembly 30013575a nhb-110/150 30014060a nhb-055/080 2 o-ring (p29) 20017923a nhb-110/150 o-ring (Φ17.5x2.7t) 20006947a nhb-055/080 3 fastener 20017724a nhb-110/150 20007853a nhb-055/080 4 high limit switch 30002558a 5 sc outlet adapter 3001...

  • Page 78

    78 appendixes 10.4.3 combustion parts assembly 1 2 3 4 5 16 15 15 18 17 10-3 10-2 19 11 15 12 13 7 6 7 8 9 10-1 14.

  • Page 79

    Appendixes 79 # description part # remark 1 ignition transformer 30010455a 2 mixed chamber 20030041a nhb-110/150 20030049a nhb-055/080 3 chamber packing 20022743a nhb-110/150 20027108a nhb-055/080 4 burner 30010246a nhb-110/150 30011854a nhb-055/080 5 burner packing 20021677a nhb-110/150 20027105a n...

  • Page 80

    80 appendixes 10.5 outdoor temperature sensor outdoor temperature sensor installation 1. Pull out the sensor body from the cap. 2. Attach the body to the wall using the screws/anchors provided with the device. 3. Run the wires into the device body through the grommet opening. 4. Connect the wires to...

  • Page 81

    Appendixes 81 10.6 outdoor reset control the outdoor reset control feature may be used to enhance energy efficiency while maintaining optimal heating performance. With the outdoor reset control, the space heating temperature setting automatically changes according to the outdoor temperature and the ...

  • Page 82: Memo

    Memo.

  • Page 83

    Getting service if your boiler requires service, you have several options for getting service: ● contact technical support at 1-800-519-8794 or on the website: www.Navien.Com. ● for warranty service, always contact technical support first. ● contact the technician or professional who installed your ...